Foldable Corrugated Plastic Produce Containers
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Solution Overview
Problem
Conventional containers for storing and transporting produce, such as wood crates and wax-coated corrugated cardboard, are not reusable, prone to injury, and lack durability during harvesting and shipping processes, while existing plastic containers require adhesives or mechanical fastening for assembly.
Innovation Solution
Development of foldable, corrugated plastic containers with integrated locking tabs and flaps that allow for assembly and disassembly without adhesives, providing a sturdy, reusable, and recyclable solution for storing and transporting produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional containers (wood crates, wax-coated corrugated cardboard) are used for storing and transporting produce, then they are readily available and easy to manufacture, but they are not reusable, prone to injury, and lack durability during harvesting and shipping processes
Solution Approach 1:
The container is designed as a foldable structure made from a single sheet of corrugated plastic, segmented into multiple panels that can be folded and locked together. This segmentation allows the container to be manufactured as a flat sheet (simple manufacturing) while providing durability when assembled (reliability during use).
Solution Approach 2:
The material transitions from conventional wood or wax-coated cardboard to corrugated plastic, changing the physical parameters of the container. This material substitution provides improved durability, reusability, and resistance to injury while maintaining ease of manufacture through die-cutting and folding processes.
2Reliability
If existing plastic containers are used, then they provide durability and reusability, but they require adhesives or mechanical fastening for assembly
Solution Approach 1:
The container incorporates self-locking tabs and slots that automatically engage with each other during the folding process, eliminating the need for adhesives or separate mechanical fasteners. The structure serves itself by using its own geometric features to secure panels together, simplifying assembly while ensuring reusability and durability.
3Ease of operation
If foldable corrugated plastic containers with integrated locking tabs and flaps are used, then assembly and disassembly can be done without adhesives, but the container design becomes more complex
Solution Approach 1:
The locking tabs, slots, and locking flaps are all integrated into a single sheet of corrugated plastic, merging multiple functional elements into one unified component. This integration simplifies manufacturing (single die-cut process) while providing ease of assembly through self-locking mechanisms, despite the increased geometric complexity of the folded structure.
4Quantity of substance
If conventional containers are used, then they provide adequate storage capacity, but they are heavier and less sustainable
Solution Approach 1:
The container transitions from heavy materials like wood to lightweight corrugated plastic, changing the density and weight parameters while maintaining storage capacity. The corrugated structure provides structural strength equivalent to wood but with significantly reduced weight, improving ease of handling and sustainability.
Data Source
AI summary
Embodiments of foldable containers, such as foldable produce containers, and related sheets and methods. In some embodiments, a container may comprise a first side panel comprising a first locking tab and a rollover flap. The rollover flap is configured to be folded with respect to the first side panel to expose the first locking tab. The first side panel further comprises a clearance aperture, wherein the first locking tab is positioned within the clearance aperture such that the clearance aperture provides spacing between the first locking tab and the rollover flap. The container may further comprise a first top panel comprising a slot for receiving the first locking tab. The first top panel may further comprise a first locking flap configured to extend adjacent to an exterior surface of the container to secure the first top panel in a closed position to at least partially enclose the container.